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Old 05-11-2014, 01:20 AM   #1
EVT_Dan
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Member#: 143534
Join Date: Mar 2007
Default 04 STi Rebuild (Lots of Gp.N/Spec.C/WRC)

So, I thought Id put together a post highlighting the rebuild of my 04 STi.
Car has 75k miles on it, originally a Connecticut car, now lives in Park City Utah.
Ive been building the car slowly. The goal was to build it with the best factory items Subaru had to offer to make for a nicely modified daily driven car.
Last year, the motor was refreshed by Solid AutoWorks in SLC
This year, Ive torn apart the rear underside for some sandblast and repaint/clear. While at it, I wanted to begin replacing items with new
Last year, the car dynod 302HP & 350lb/ft Torque at 4,200ft and 91 octane on a hub dyno
Using the racecar scales at work, the car weighed 3090lbs with fuel

Current mod list
Perrin FMIC Kit
SPT Intake w/K&N
GTSpec Equal length headers
GTSpec upipe
Cobb 3 Turbo back, no cats
STi 3 Puck carbon ceramic clutch
Gp.N STi lightweight Flywheel
GP.N Short Shift with bushings
Gp. N rear brakes
STi Titanium Front Strut Bar
STi Aluminum Rear Strut Bar
BC BR Inverted Coilovers
Rota RT5 Rims
Genuine WRC Carbon Fiber Side-View mirrors
Genuine WRC Rear Spoiler (2003 Bugeye)
Spec C STi Aluminum trunk lid
Ver.7 Full interior
ProSport Boost/Oil/Water gauges in ATI pod
Rally Armor Mudflaps

Items currently being installed
Gp.N STi Quick Steering Rack
Baer Big brake Kit (Front)
Spec C Roof Scoop
Whiteline Lower Arm Bar
Whiteline 24mm Front Sway bar
Whiteline 22mm Rear Sway bar
Whiteline Aluminum Rear sway bar mounts
Perrin Front / Rear Endlinks
07 STi Aluminum Rear Lat Links
STi Pink Rear Trailing Arms
Samco Hoses
Lightweight Braille Battery

Items being removed for weight savings
Front U-Brace
Rear crash beam
AC

Here are some photos of the progress




Used Latt before

After + Ceramic Clear



Tired Unammused Beagle
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Old 05-11-2014, 01:20 AM   #2
EVT_Dan
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Join Date: Mar 2007
Default



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Old 05-11-2014, 09:11 AM   #3
AutoPrue
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Join Date: May 2006
Chapter/Region: NESIC
Location: @atomic_bugeye
Default

Nice job man cant wait to see it all back together. Nice choice on the wing too.
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Old 05-11-2014, 12:36 PM   #4
561wrx
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Member#: 166427
Join Date: Dec 2007
Chapter/Region: South East
Location: boynton bch, fl
Vehicle:
03 wrx

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more please!
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Old 05-11-2014, 02:01 PM   #5
Brandon2k13
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Member#: 376571
Join Date: Dec 2013
Chapter/Region: NESIC
Location: Lil' Rhode Island.
Vehicle:
2015 WRX STI
Launch Edition - WRB

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Looks like it's gonna be an awesome build!
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Old 05-26-2014, 01:06 AM   #6
EVT_Dan
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Default

Made a little progress today

Driveshaft, rear subframe, T-Brace, Rear diff, lats and trailing arms all hung.

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Old 05-26-2014, 09:01 AM   #7
TofuMan
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Member#: 158618
Join Date: Sep 2007
Chapter/Region: BAIC
Location: Bay Area, CA
Vehicle:
2004 WRX
PSM

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Beautiful work.
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Old 05-28-2014, 03:56 AM   #8
REXXYY
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Awesome work!! Subscribed!!
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Old 05-31-2014, 02:22 AM   #9
EVT_Dan
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Default

A little before and after as it goes together



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Old 05-31-2014, 08:27 AM   #10
Se7enrex
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Member#: 124283
Join Date: Aug 2006
Location: Minneapolis, MN
Vehicle:
2000 RS/STI/WRX

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Did you end up painting it? It looks like it's still raw?
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Old 05-31-2014, 02:47 PM   #11
EVT_Dan
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Default

After everything was sand blasted, I had a shop prime and paint the uprights and subframe. For anything aluminum, they used a ceramic clear to protect the bare metal.
If I didn't buy new hardware, I stripped, primed and painted all original hardware.
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Old 05-31-2014, 03:01 PM   #12
Bikelok
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Member#: 254851
Join Date: Aug 2010
Chapter/Region: BAIC
Location: Nor-Cal Bay Area
Vehicle:
2002 Wrx wagon 5mt
PSM

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Very nice work!

Keep posting.

No A/C on a daily driver though. Ouch.
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Old 05-31-2014, 08:18 PM   #13
carlos.danger
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Member#: 363268
Join Date: Jul 2013
Location: California
Vehicle:
2015 WRX STi
WRB

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having a huge workspace really helps with projects like this.

looks like this will come together nicely. good work!
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Old 05-31-2014, 09:07 PM   #14
EVT_Dan
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Default

Quote:
Originally Posted by Bikelok View Post
Very nice work!

Keep posting.

No A/C on a daily driver though. Ouch.
Don't say that ! Its still in the car, fully functional. I keep debating taking it out or not. To be honest the car is becoming less daily driver and more toy.
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Old 10-01-2014, 12:33 AM   #15
REXXYY
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Any updates?
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Old 10-01-2014, 11:22 PM   #16
habskater11
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Member#: 363903
Join Date: Jul 2013
Chapter/Region: Tri-State
Location: nj
Vehicle:
2007 wrx 5 door
wrb

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I'm sure your car is happy to shake that rust off
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Old 10-02-2014, 01:00 AM   #17
EVT_Dan
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Join Date: Mar 2007
Default

Well, the rear came together so nice, I couldn't bare to think of not touching the front.

Therefor, the engine has been pulled ! I mean, who wouldn't, right ?

Plans now
Rotated turbo set-up - 3076R or similar
Rotated intake manifold
Cosworth internals
ABS delete with new brake lines throughout the engine bay
Quick steering rack
JPM Coachworks 1/8 thicker steering wheel
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Old 10-02-2014, 04:09 AM   #18
MGigantelli44
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Member#: 234591
Join Date: Jan 2010
Chapter/Region: NWIC
Location: Vancouver, Wa
Vehicle:
2004 WRX STI JBP

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moar pics! This is awesome
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Old 10-02-2014, 04:14 AM   #19
old_duwel
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Member#: 18175
Join Date: Apr 2002
Location: Okinawa, Japan
Vehicle:
99 STI RA Ltd #450
WRB blue

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I want to do my crossmember in orange or red
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Old 10-02-2014, 03:20 PM   #20
art@grimmspeed
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Member#: 301037
Join Date: Nov 2011
Chapter/Region: MWSOC
Location: Minneapolis, MN
Vehicle:
2004 Forester XT
Aspen White

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Great attention to detail, I would love to do something similar but the guys in our warehouse get extremely upset when I start laying out my car parts on the shop floor for some reason
-Art
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Old 10-03-2014, 12:27 AM   #21
REXXYY
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Default

Quote:
Originally Posted by EVT_Dan View Post
Well, the rear came together so nice, I couldn't bare to think of not touching the front.

Therefor, the engine has been pulled ! I mean, who wouldn't, right ?

Plans now
Rotated turbo set-up - 3076R or similar
Rotated intake manifold
Cosworth internals
ABS delete with new brake lines throughout the engine bay
Quick steering rack
JPM Coachworks 1/8 thicker steering wheel
Awesome !!
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Old 10-03-2014, 12:38 AM   #22
Boost is Best
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Member#: 102858
Join Date: Dec 2005
Chapter/Region: SCIC
Location: Los Angeles
Vehicle:
2003 Bugeye
Stroked & Aggressive

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Rad! In for moooore
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Old 12-06-2014, 02:01 AM   #23
EVT_Dan
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Member#: 143534
Join Date: Mar 2007
Default

Hey guys !
Couple updates for you.
First off, user Garris Morrocco88 is building me a kick-ass rotated set-up.
His thread regarding these rotated kits is
http://forums.nasioc.com/forums/show....php?t=2412144

Im going to a brand new Garrett GTX3071R. with a .63AR - T3 inlet and 3 V-band outlet with a 44mm Tial external wastegate. For now, the internals of the engine will remain stock. So, Im looking for quick spool with perhaps 380ish at the wheels till I build an engine.


Also, Ive decided to do a massive clean on the engine compartment. ABS is completely deleted (Ill be running new front brake lines) AC is removed also. The wire harness is getting tucked in the obvious places. The fuse box is getting moved partially to the inner fender. Ive got a special idea for access to the box. Ill update with photos soon.
Finally, the engine bay is going to be painted flat white.
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